Modular headliner assembly with air curtains

ABSTRACT

A headliner and air bag assembly includes a headliner having a left and right side edges and a carrier assembly having left and right rails extending along the left and right side edges of the headliner, respectively. The carrier assembly also includes a cross-member connecting the left and right rails. The left and right rails support at least one air bag assembly, and the carrier assembly provides structural support for the headliner and for the air bag assembly to prevent bending of the headliner during installation.

TECHNICAL FIELD

[0001] The present invention relates to a vehicle headliner assemblyincluding a carrier assembly which supports at least one air curtain onthe headliner and adds structural integrity to the headliner assembly.

BACKGROUND OF THE INVENTION

[0002] Modularity in vehicle components is important for automanufacturers because it simplifies the auto assembly process, therebyreducing parts. Recently, automotive interior headliners have been mademodular by providing a headliner subassembly which includes overheadconsoles, electronics, light sources, air curtains, and air curtaindeployment equipment mounted on the headliner. The headliner and thesevarious components are installed as a single unit subassembly into avehicle.

[0003] One problem with the modularity concept in headliners is that theattachment of various heavy components around the periphery of theheadliner may cause flexing or bending of the headliner, which can makehandling and assembly difficult.

DISCLOSURE OF INVENTION

[0004] The present invention overcomes the problem described above byproviding a carrier assembly which is adhesively secured to theperiphery of the headliner for supporting the air bag system and addingstructural integrity to the headliner subassembly for installation inthe vehicle. The air bag igniter is mounted to the rear of the headlinerso that it need not be mounted behind an overhead console.

[0005] More specifically, the present invention provides a headliner andair bag assembly including a headliner having left and right side edges.A carrier assembly includes left and right rails extending along theleft and right side edges of the headliner, respectively, and across-member connecting the left and right rails. The left and rightrails support at least one air bag assembly, and the carrier assembly isconfigured to provide structural support for the headliner and for theair bag assembly. Preferably, the carrier assembly is adhesively securedto the periphery of the headliner.

[0006] Another aspect of the invention provides a method of assembling avehicle headliner and air bag assembly including the steps of: a)providing a plastic carrier assembly including left and right rails anda cross-member; b) positioning inflatable air curtains within the leftand right rails; c) positioning an igniter assembly in the cross-memberfor deploying the air curtains; and d) attaching the carrier assembly toa headliner having left and right side edges such that the left andright rails extend along the left and right side edges, and thecross-member connects the left and right rails to structurally supportthe weight of the headliner and air bag assembly during installation.

[0007] Accordingly, an object of the invention is to provide a modularheadliner assembly including a carrier assembly which supports theweight of the headliner and of various heavy components attached aroundthe periphery of the headliner, such as the air curtains and inflatorassembly, to prevent flexing or bending of the headliner duringinstallation.

[0008] The above object and other objects, features, and advantages ofthe present invention are readily apparent from the following detaileddescription of the best mode for carrying out the invention when takenin connection with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

[0009]FIG. 1 shows a perspective view of a headliner and air bagassembly in accordance with the present invention;

[0010]FIG. 2 shows an exploded perspective view of the assembly of FIG.1;

[0011]FIG. 3 shows a partial schematic cross-sectional view of theheadliner and air bag assembly of FIG. 1 installed in a vehicle;

[0012]FIG. 4 shows a partial vertical cross-sectional view taken throughthe rear header of the headliner and air bag assembly of FIG. 1;

[0013]FIG. 5 shows a partial vertical cross-sectional view of theassembly of FIG. 1 attached to a vehicle, the section being takenthrough one of a plurality of Forrester fasteners in the assembly;

[0014]FIG. 6 shows a partial cross-sectional view of a rear header inaccordance with the invention; and

[0015]FIG. 7 shows a partial vertical cross-sectional view of a siderail in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0016]FIGS. 1 and 2 show a headliner and air bag assembly 10 inaccordance with the present invention. The headliner and air bagassembly 10 includes a headliner 12, which is typically a PET, or otherthermoformable material. A plastic carrier 14 includes left and rightrails 16,18, and a rear header 20 which is attached, such as by sonicwelding, between the left and right rails 16,18 to form the carrier 14.

[0017] An igniter assembly 22, which includes a canister and inflator,is secured to the rear header 20, and polypropylene or canvas tubes24,26 extend from the igniter assembly 22 for deploying the air curtains28,30.

[0018] The air curtains 28,30 are housed within the left and right rails16,18, along with EPP foam countermeasures 32,34 for head impactprotection. The air curtains 28,30 are configured for deployment alongthe side windows of a vehicle.

[0019] Once the countermeasures 32,34 and air curtains 28,30 have beenassembled into the left and right rails 16,18, a layer of SCRIM could beplaced over this carrier subassembly to assure that debris does notinadvertently fall into the air curtain area.

[0020]FIG. 3 shows a vertical cross-sectional view of the headliner andair bag assembly 10 secured to a vehicle roof structure 36. As shown,the headliner 12 is secured to the carrier 18 by hot melt adhesives38,40. Preferably, the hot melt adhesives 38,40 comprise adhesive numberHM7239 from Bostik Hot Melt Adhesives of Middleton, Mass.

[0021] As shown, a coat hook 42 includes a base 44 with a bolt 46 andZ-clip 48 which secure the carrier 18 to the headliner 12 to form aheadliner subassembly which is installed into the vehicle simply bypushing the Z-clips 48 into the openings formed in the roof structure36.

[0022] As shown in FIG. 3, hot melt adhesive 50 also secures thecountermeasure 34 to the carrier 18.

[0023] In this manner, the coat hook 42 holds the portion of theheadliner 12 shown in FIG. 3 to the carrier 18 for handling. The coathook 42 is illustrative, and may be replaced by a grab handle or assisthandle. For example, as shown in FIG. 1, apertures 52,54 are provided inthe left rail 16 at a location in which a grab handle would be provided.The grab handle would be provided with a similar structure as the bolt46 and Z-clip 48 shown in FIG. 3 for attachment to the headliner 12. Ofcourse, multiple coat hook and assist handle attachments could be usedthroughout the assembly to secure various portions of the rails 16,18 tothe headliner 12 to provide structural integrity to the assembly 10.

[0024] As shown in FIG. 2, attachment locations 56 indicate the presenceof a Forrester fastener, shown in FIG. 4. FIG. 4 shows a verticalcross-sectional view taken through the rear header 20, and indicates oneof several Forrester fasteners 58 which are secured about the peripheryof the carrier 14. Preferably, the Forrester fastener is a pump fastenerfrom Forrester Fastener Company of Clinton Township, Mich. The adhesivein the fastener is preferably an ethyl cyanoacrylate, such as adhesive#1414 from Loctite Company of Rocky Hill, Conn. Also, each Forresterfastener 58 includes opposing stand-offs 60,62 on opposing sides thereoffor transferring forces from the headliner 12 to the fastener 58.Forrester fasteners are configured with a plunger arrangement andinclude glue therein, such that when the plunger is depressed the glueis dispensed for attaching the carrier 20 to the roof structure 36. Whenthe operator pushes on a marked location 64 (a location marker such as asticker would be placed on the headliner 12), the forces would betransferred through the stand-offs 60,62 to the Forrester fastener 58 sothat attachment glue is dispensed to secure the carrier 20 to the roofstructure 36. These Forrester fasteners 58 would be positioned at eachlocation 56 illustrated in FIG. 2 for attachment to the roof structure36 of the vehicle.

[0025]FIG. 5 shows a cross-sectional view taken through one of theForrester fastener locations 56 in the right rail 18. As shown in FIG.5, stand-offs 61,63 are provided for transferring forces from theheadliner 12 to the Forrester fastener 58, as described above withreference to FIG. 4, for dispensing glue to attach the headliner to thevehicle roof.

[0026] Turning to FIG. 6, a vertical cross-sectional view is shown ofthe rear header 20, and FIG. 7 shows a vertical cross-sectional view ofa right rail 18. These components are preferably ABS plastic materials.

[0027] A subassembly including the carrier 14 and the air bag assemblyincluding the igniter assembly 22, tubes 24,26, and air curtains 28,30,as well as the countermeasures 32,34 are attached to the headliner 12 ina nesting fixture with the hot melt adhesive 38,40.

[0028] When the air curtains 28,30 deploy, the hot melt adhesive 40tears away from the headliner 12 (such as by tearing a SCRIM backing offof the headliner 12), so that the peripheral edge 70 of the headliner12, shown in FIG. 3, displaces downward to provide clearance to enabledeployment of the air curtains 28,30 along the vehicle side windows.

[0029] Also, by mounting the igniter assembly 22 in the rear of theheadliner assembly, the need for housing the igniter assembly underneaththe console is eliminated, thereby maximizing the usable space behindthe overhead console.

[0030] While the best mode for carrying out the invention has beendescribed in detail, those familiar with the art to which this inventionrelates will recognize various alternative designs and embodiments forpracticing the invention within the scope of the appended claims.

What is claimed is:
 1. A headliner and air bag assembly (10) comprising:a headliner (12) having left and right side edges; a carrier assembly(14) having left and right rails (16,18) extending along the left andright side edges of the headliner, respectively, and a cross-member (20)connecting the left and right rails (16, 18); said left and right rails(16, 18) supporting left and right air bag assemblies respectively (28,30), and said carrier assembly (14) being configured to providestructural support for the headliner and for said at least one air bagassembly (28, 30) to prevent bending of the headliner duringinstallation; and wherein an igniter assembly (22) is provided forinflating the left and right air curtains (28, 30) of said airbagassemblies; characterized in that said left and right air curtains (28,30) are housed within said left and right rails (16, 18), respectively,said igniter assembly (22) being supported by the cross-member (20) andin that said carrier assembly is adhesively secured (38, 40) to theperiphery (70) of the headliner (12) such that upon inflation of saidleft and right air curtains (28, 30) the adhesive attachment (40) alongthe left and right side edges of the headliner is torn to enabledeployment of said air curtains (28, 30).
 2. The headliner and air bagassembly (10) of claim12, wherein said carrier assembly (14) comprisesinjection molded plastic.
 3. The headliner and air bag assembly (10) ofclaim 1, further comprising foam countermeasures (32, 34) supported bysaid left and right rails (16, 18).
 4. The headliner and air bagassembly (10) of claim 3, further comprising a layer of SCRIM enclosingthe air curtains (28, 30) and foam countermeasures (32, 34) within theleft and right rails (16, 18).
 5. The headliner and air bag assembly(10) of claim 1, further comprising a vehicle interior utility componentsecuring the carrier assembly (14) to the headliner (12).
 6. Theheadliner and air bag assembly (10) of claim 5, wherein said utilitycomponent comprises a caot hook assembly (42).
 7. The headliner and airbag assembly (10) of claim 1, wherein said carrier assembly (14)includes at least one pump fastener (58) for selectively dispensingadhesive to secure the carrier assembly (14) to a vehicle roof (36). 8.The headliner and air bag assembly (10) of claim 7, wherein said carrierassembly (14) includes standoffs (61, 63) on opposing sides of the pumpfastener (58) for transferring forces from the headliner (12) to thepump fastener (58).
 9. A method of assembling a vehicle headliner andair bag assembly (10) comprising: providing a plastic carrier assembly(14) including left and right rails (16, 18) and a cross-member (20);positioning inflatable air curtains (28, 30) within the left and rightrails (16, 18); positioning an igniter assembly (22) in the cross-member(20) for inflating the air curtains (28, 30); and attaching the carrierassembly (14) to a headliner (12) having left and right side edges suchthat the left and right rails (16, 18) extend along the left and rightside edges, and the cross-member (20) connects the left and right rails(16, 18) to structurally support the weight of the headliner (12) andair bag assembly (28, 30) during installation, wherein said attachingstep comprises adhesively attaching the carrier assembly (14) to theheadliner (12) such that inflation of the air curtains (28, 30) willtear the adhesive attachment along the left and right side edges of theheadliner (12) for deployment along side windows of a vehicle in whichthe assembly is installed.
 10. The method of claim 9, further comprisingpositioning foam countermeasures (32, 34) within the left and rightrails (16, 18) prior to said attaching of the carrier assembly (14) tothe headliner (12).
 11. The method of claim 9, wherein said attachingstep comprises attaching the cross-member (20) along a rear edge of theheadliner (12).